Refrigerated merchandiser with dual air curtain

ABSTRACT

A refrigerated merchandiser including a case defining a product display area, and a shelf supported by the case within the product display area. The case includes a base that is disposed below the product display area and a canopy that is disposed substantially above the product display area. The shelf includes an air discharge duct that is configured to direct a first air curtain generally downward from the shelf into the product display area toward the base, and an air return duct that is configured to receive at least a portion of a second air curtain discharged into the product display area from above the shelf.

RELATED APPLICATIONS

This patent application claims priority to U.S. Patent Application Ser.No. 61/086,038 filed Aug. 4, 2008, the entire contents of which arehereby incorporated by reference.

BACKGROUND

The present invention relates to a refrigerated merchandiser thatincludes an air curtain. More particularly, the present inventionrelates to a refrigerated merchandiser that includes a product displayarea, a primary air curtain, and a secondary air curtain.

In conventional practice, supermarkets and convenience stores areequipped with refrigerated merchandisers that have open display portionsfor presenting fresh food or beverages in a product display area tocustomers while maintaining the fresh food and beverages (i.e., foodproduct) in a refrigerated environment. Typically, refrigeratedmerchandisers include a curtain of cool, refrigerated air that passesdownward across the open face portion of the merchandiser to form aflowing boundary of air between the product display area and the rest ofthe store. The air curtain is generated by an airflow through apassageway of the refrigerated merchandiser that is cooled by one ormore evaporators disposed in the passageway, and that is discharged froman outlet in a canopy of the merchandiser. The air curtain assists inkeeping refrigerated air within the product display area to cool thefood product and protects the product display area from ambient air inthe surrounding store. Warmer ambient conditions surrounding therefrigerated merchandiser increase cooling requirements of themerchandiser and can undesirably increase the temperature of the foodproduct in the product display area.

Some refrigerated merchandisers incorporate multiple air curtains tolimit entrainment of ambient air that can occur in a single air curtainrefrigerated merchandiser, and to maintain the product display area atdesired temperatures. Refrigerated merchandisers with two or moreadjacent air curtains include an outer air curtain that has a slightlyhigher temperature than the inner air curtain, so as to protect thecolder, inner air curtain from the impact of ambient air surrounding themerchandiser. These multiple air curtain refrigerated merchandisers aredesigned to limit problems of entrainment of ambient air into thecolder, inner air curtain. However, such designs are still susceptibleto the intrusion of ambient air into the refrigerated air curtain.

SUMMARY

In one construction, the invention provides a refrigerated merchandiserincluding a case defining a product display area, and a shelf supportedby the case within the product display area. The case includes a basethat is disposed below the product display area and a canopy that isdisposed substantially above the product display area. The shelfincludes an air discharge duct that is configured to direct a first aircurtain generally downward from the shelf into the product display areatoward the base, and an air return duct that is configured to receive atleast a portion of a second air curtain discharged into the productdisplay area from above the shelf.

In another construction, the invention provides a refrigeratedmerchandiser including a case defining a product display area, and aplurality of shelves supported by the case within the product displayarea. The case includes a base that is disposed below the productdisplay area and a canopy that is disposed substantially above theproduct display area. The canopy is configured to discharge a first aircurtain toward the base. The plurality of shelves include an upper shelfthat has an air discharge duct, and a lower shelf that is positionedvertically below the upper shelf and that has an air return duct. Atleast one of the canopy and the upper shelf is configured to discharge asecond air curtain substantially vertically through the product displayarea such that the second air curtain is at least partially received bythe air return duct of the lower shelf.

In yet another construction, the invention provides a method ofconditioning a product display area of a refrigerated merchandiser. Themethod includes providing a case that includes a base disposed below theproduct display area and a canopy that is disposed substantially abovethe product display area, and providing a shelf that is supported by thecase within the product display area. The method also includesdischarging a first air curtain generally downward from the shelf intothe product display area toward the base, discharging a second aircurtain generally downward into the product display area from above theshelf, and receiving at least a portion of the second air curtain via anair return duct of the shelf.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic side view of a refrigerated merchandiser embodyingthe present invention.

FIG. 2 is an enlarged schematic side view of a portion of therefrigerated merchandiser of FIG. 1.

FIG. 3 is a section view of a portion of the refrigerated merchandiserof FIG. 1.

FIG. 4 is a section view of a shelf of the refrigerated merchandiser ofFIG. 1.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it is to be understood thatthe phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. The use of“including,” “comprising,” or “having” and variations thereof herein ismeant to encompass the items listed thereafter and equivalents thereofas well as additional items.

FIG. 1 shows a refrigerated merchandiser 10 that may be located in asupermarket or a convenience store (not shown) for presenting freshfood, beverages, and other food product (not shown) to customers. Therefrigerated merchandiser 10 includes a case 15 having a base 20, a rearwall 25, and a canopy 30. The area partially enclosed by the base 20,the rear wall 25, and the canopy 30 defines a product display area 35that stores food product in the case 15 and that is accessible bycustomers through an opening 37 adjacent the front of the case 15.

The base 20 is disposed substantially below the product display area 35and can be supported by a floor or support surface (not shown) of thesupermarket. The base 20 defines a lower portion of the product displayarea 35 and can support a portion of the food product in the case 15.The base 20 further defines a lower discharge flue 40, a lowercirculation flue 45, and a lower return flue 50, and includes a primaryinlet 55 and a secondary inlet 60 that is located outward from theprimary inlet 55 adjacent the opening 37.

The lower discharge flue 40 is in fluid communication with the primaryinlet 55 and conducts an airflow 70 substantially horizontally throughthe base 20 from the primary inlet 55. The lower circulation flue 45 isin fluid communication with the secondary inlet 60 and conducts acirculated airflow 75 substantially horizontally through the base 20from the secondary inlet 60. The primary and secondary inlets 55, 60 arepositioned to receive surrounding air in a substantially verticaldirection to direct the surrounding air into the lower discharge flue 40and the lower circulation flue 45, respectively.

The lower return flue 50 is in fluid communication with the lowerdischarge flue 40 in the base 20 adjacent the front of the case 15 todirect a return airflow 80 from the lower return flue 50 into the lowerdischarge flue 40 downstream of the primary inlet 55. In the illustratedconstruction, the lower discharge flue 40 is positioned above the lowerreturn flue 50, although other relative positions of the lower dischargeflue 40 and the lower return flue 50 are possible and considered herein.The lower circulation flue 45 is generally located below the lowerdischarge flue 40 and the lower return flue 50.

FIGS. 1 and 2 show that the rear wall 25 defines a rear portion of theproduct display area 35 that includes a rear circulation flue 85, a reardischarge flue 90, and a rear return flue 95. In the illustratedrefrigerated merchandiser 10, the rear wall 25 also includes apertures100 that fluidly couple the rear discharge flue 90 with the productdisplay area 35 and that allow at least some of the airflow 70 in therear discharge flue 90 to enter the product display area 35. In otherconstructions, the rear wall 25 does not include the apertures 100.

The rear circulation flue 85 is in fluid communication with the lowercirculation flue 45, and is positioned adjacent the back of the case 15behind the rear discharge flue 90 and the rear return flue 95 to directthe circulated airflow 75 in a substantially vertical direction towardthe canopy 30. The rear discharge flue 90 is in fluid communication withthe lower discharge flue 40 to direct the airflow 70 in a substantiallyvertically upward direction. The rear return flue 95 is in fluidcommunication with the lower return flue 50 to direct the return airflow80 in a substantially vertically downward direction.

In the construction of the refrigerated merchandiser 10 that isillustrated in FIG. 1, the rear discharge flue 90 and the rear returnflue 95 are generally offset from each other such that the reardischarge flue 90 is located in front of the rear return flue 95relative to the front of the case 15 (i.e., the rear discharge flue 90is horizontally closer to the product display area 35). In otherconstructions, the rear discharge flue 90 can be behind the rear returnflue 95.

FIG. 3 shows another construction of the rear discharge flue 90 and therear return flue 95. In this construction, the rear discharge flue 90and the rear return flue 95 are separated from each other by wallmembers 105 that extend vertically between the base 20 and the canopy30, and that further extend from the wall that partially defines therear circulation flue 85 to the interior portion of the rear wall 25that partially defines the product display area 35. The wall members 105are positioned in the rear wall 25 to define a plurality of reardischarge flues 90 and a plurality of rear return flues 95 such that therear discharge flues 90 and the rear return flues 95 are orientedvertically in the rear wall 25 and are alternatingly positioned across ahorizontal length of the case 15. In other words, each of the wallmembers 105 is located between and shared by one rear discharge flue 90and one rear return flue 95. In other constructions, the rear dischargeflue 90 and the rear return flue 95 can be arranged in the rear wall 25in other ways.

The canopy 30 is disposed substantially above the product display area35 and defines an upper portion of the product display area 35 that hasan upper discharge flue 110 and an upper circulation flue 115 that ispositioned outward from the upper discharge flue 110. The canopy 30includes a primary outlet 120 that is disposed adjacent the productdisplay area 35, and a secondary outlet 125 that is located outward fromthe primary outlet 120 adjacent an end of the canopy 30. The upperdischarge flue 110 is in fluid communication with the rear dischargeflue 90 and conducts the airflow 70 substantially horizontally throughthe canopy 30 toward the primary outlet 120. The upper circulation flue115 is in fluid communication with the rear circulation flue 85 andconducts the circulated airflow 75 substantially horizontally throughthe canopy 30 toward the secondary outlet 125.

FIGS. 1 and 2 show that the merchandiser 10 also includes shelves 130that are disposed within the product display area 35 to support the foodproduct. Each shelf 130 is attached to the rear wall 25 at one end, andextends outward from the rear wall 25 toward the front of the case 15.FIGS. 2 and 4 show that each shelf 130 defines a discharge duct 135 andtwo return ducts 140, and includes a discharge outlet 145 and a returninlet 150. The discharge duct 135 is in fluid communication with therear discharge flue 90 and the discharge outlet 145, and directs theairflow 70 substantially horizontal from the rear discharge flue 90toward the discharge outlet 145. The discharge duct 135 in each shelf islocated substantially below the return duct 140, and the dischargeoutlet 145 is located below the associated return inlet 150 adjacent thefree or suspended end of each shelf 130 at the front of the case 15. Thereturn ducts 140 are in fluid communication with the rear return flue 95and the return inlet 150, and direct the return airflow 80 substantiallyhorizontally from the return inlet 150 toward the rear return flue 95.In some constructions, each shelf 130 can include one or more than tworeturn ducts 140. Similarly, each shelf 130 can include more than onedischarge duct 135.

The lower discharge flue 40, the rear discharge flue 90, and the upperdischarge flue 110 define a first portion of a primary air passagewaythat directs the airflow 70 from the primary inlet 55 to the primaryoutlet 120. The lower discharge flue 40, the rear discharge flue 90, andthe discharge ducts 135 of the shelves 130 define a second portion ofthe primary air passageway that directs the airflow 70 from the primaryinlet 55 to the discharge outlets 145. The airflow 70 that is dischargedfrom the primary outlet 120 and the airflow 70 that is discharged fromeach of the discharge outlets 145 define primary air curtains 155.

The return duct 140 of each shelf 130, the rear return flue 95, and thelower return flue 50 define a return air passageway that directs thereturn airflow 80 from the associated return inlet 150 to the lowerdischarge flue 40. The return airflow 80 in the return air passageway isfluidly combined or amalgamated with the airflow 70 in the primary airpassageway in the lower discharge flue 40 adjacent the front of the case15 and downstream of the primary inlet 55.

Each of the primary air curtains 155 that is discharged from the primaryoutlet 120 and the discharge outlets 145 are defined as short throw ormodular air curtains that travel generally downward from the associatedoutlet 120, 145 into the product display area 35 a relatively shortdistance. For example, the primary air curtain 155 that is dischargedfrom the primary outlet 120 of the canopy 30 travels generally downwardtoward the uppermost shelf 130 in the product display area 35. In theillustrated construction, the return inlet 150 of the uppermost shelf130 receives at least a substantial portion of the primary air curtain155 that is discharged from the primary outlet 120. Any remainingportion of the primary air curtain 155 that is not received by thereturn inlet 150 of the uppermost shelf 130 continues in a generallydownward direction.

Similarly, the primary air curtain 155 that is discharged from eachshelf 130 is at least substantially received by the respective inlet(i.e., the primary inlet 55 or the return inlet 150) that is locateddirectly below the discharge outlet 145 from which the primary aircurtain 155 is discharged. Thus, the primary air curtains 155 travelrelatively short distances between the canopy 30 and the uppermost shelf130, between adjacent shelves 130, and/or between the lowermost shelf130 and the base 20. In some constructions, the primary and returninlets 55, 150 receive substantially all of the short throw primary aircurtains 155 that are discharged from the associated outlet 120, 145that is located directly above the respective inlet 55, 150. Generally,any remaining portion of each short throw primary air curtain 155 thatis not received by the return inlet 150 of the shelf 130 that isdirectly below the associated discharge outlet 145 continues in agenerally downward direction through the product display area 35.

The lower circulation flue 45, the rear circulation flue 85, and theupper circulation flue 115 define a secondary air passageway thatdirects the circulated airflow 75 from the secondary inlet 60 to thesecondary outlet 125. The circulated airflow 75 that is discharged fromthe secondary outlet 125 is in the form of a secondary air curtain 160,and is generally defined as a long throw air curtain that travelsgenerally downward from the secondary outlet 125 toward the secondaryinlet 60. In the illustrated construction, the primary air curtains 155and the secondary air curtain 160 are directed generally downwardlyacross the front of the case 15 adjacent the product display area 35 tocool the food product. In other constructions, the refrigeratedmerchandiser 10 may not include the lower circulation flue 45, the rearcirculation flue 85, and the upper circulation flue 115 that define thesecondary air passageway. In these constructions, the refrigeratedmerchandiser does not include the secondary air curtain 160.

The secondary air curtain 160 is located adjacent and outside of theprimary air curtains 155 to assist in forming a barrier between ambientair surrounding the case 15 and the product display area 35. In someconstructions, the secondary air curtain 160 may be warmer than theprimary air curtains 155 and cooler than the surrounding ambient air.Generally, the secondary air curtain 160 is directed downward outside ofthe primary air curtains 155 to buffer the primary air curtains 155 fromthe relatively warm ambient air surrounding the case 15.

The primary and secondary air curtains 155, 160 cooperate to define adual air curtain adjacent the front of the case 15. Portions of the dualair curtain may be drawn into one or both of the primary and secondaryinlets 55, 60 for recirculation. The dual air curtain, among otherthings, helps to maintain the air temperature in the product displayarea 35 within a standard temperature range. For example, for mediumtemperature cases the temperature range is 32 to 41 degrees Fahrenheitas determined by the Food and Drug Administration (“FDA”) Food Code.

The refrigerated merchandiser 10 also includes some components of arefrigeration system (not entirely shown) therein. As shown in FIG. 1,one or more fans 165 can be located in the primary and/or secondary airpassageway to generate the airflow 70 and the circulated airflow 75 bydrawing air into the primary and secondary air passageways from theprimary and secondary inlets 55, 60 and forcing the air through theremaining portions of the respective air passageways. An evaporator 170is disposed in the primary air passageway to refrigerate the airflow 70.As is known in the art, the evaporator 170 is configured to receive asaturated refrigerant that has passed through an expansion valve (notshown). The saturated refrigerant is evaporated as it passes through theevaporator 170 as a result of absorbing heat from the airflow passingover the evaporator 170. The absorption of heat by the refrigerantallows the temperature of the airflow to decrease as it passes over theevaporator 170. The heated or gaseous refrigerant then exits theevaporator 170 and is pumped back to one or more compressors (not shown)for re-processing into the refrigeration system. In other constructions,the evaporator 170 could be replaced with another heat exchanger (e.g.,secondary heat exchanger, etc.) that allows the absorption of heat fromthe circulated air into a refrigerant or other heat-transfer fluidwithin the heat exchanger.

Various features and advantages of the invention are set forth in thefollowing claims.

1. A refrigerated merchandiser comprising: a case defining a productdisplay area and including a base disposed below the product displayarea and a canopy disposed substantially above the product display area;and a shelf supported by the case within the product display area andincluding an air discharge duct configured to direct a first air curtaingenerally downward from the shelf into the product display area towardthe base, the shelf further including an air return duct configured toreceive at least a portion of a second air curtain discharged into theproduct display area from above the shelf.
 2. The refrigeratedmerchandiser of claim 1, wherein the canopy defines an upper flueconfigured to direct the second air curtain into the product displayarea from above the shelf.
 3. The refrigerated merchandiser of claim 1,wherein the shelf is a first shelf of the refrigerated merchandiser,wherein the refrigerated merchandiser further comprises a second shelfpositioned above the first shelf and including an air discharge ductconfigured to direct the second air curtain generally downward towardthe first shelf.
 4. The refrigerated merchandiser of claim 1, whereinthe case further defines a rear discharge flue in communication with theshelf to distribute a first airflow to the air discharge duct, and arear return flue in communication with the shelf to receive a secondairflow from the air return duct.
 5. The refrigerated merchandiser ofclaim 4, wherein the case includes a plurality of rear discharge fluesand a plurality of rear return flues alternatingly positioned across ahorizontal length of the case such that one rear discharge flue ispositioned adjacent at least one rear return flue.
 6. The refrigeratedmerchandiser of claim 1, wherein the shelf defines one air dischargeduct and at least two air return ducts.
 7. The refrigerated merchandiserof claim 6, wherein the air discharge duct is located substantiallylower than the air return ducts.
 8. The refrigerated merchandiser ofclaim 1, further comprising an evaporator coupled to the case andconfigured to refrigerate an airflow within the case, and wherein thecase defines a primary passageway having a first portion configured todirect the airflow toward the canopy, and a second portion configured todirect the airflow toward the shelf.
 9. The refrigerated merchandiser ofclaim 1, wherein the first air curtain discharged from the shelf and theportion of the second air curtain received by the shelf are defined asshort throw air curtains configured to travel through the productdisplay area a distance less than the full height of the product displayarea.
 10. A refrigerated merchandiser comprising: a case defining aproduct display area and including a base disposed below the productdisplay area and a canopy disposed substantially above the productdisplay area, the canopy configured to discharge a first air curtaintoward the base; and a plurality of shelves supported by the case withinthe product display area, the plurality of shelves including an uppershelf having an air discharge duct, and a lower shelf positionedvertically below the upper shelf and having an air return duct, at leastone of the canopy and the upper shelf configured to discharge a secondair curtain substantially vertically through the product display areasuch that the second air curtain is at least partially received by theair return duct of the lower shelf.
 11. The refrigerated merchandiser ofclaim 10, wherein the first air curtain is defined as a long throw aircurtain configured to travel through the product display area from thecanopy to the base a distance substantially the height of the productdisplay area, and wherein the second air curtain is defined as a shortthrow air curtain configured to travel through the product display areafrom at least one of the canopy and the upper shelf toward the base adistance less than the full height of the product display area.
 12. Therefrigerated merchandiser of claim 10, wherein the case further definesa rear discharge flue in communication with the upper shelf todistribute a first airflow to the air discharge duct, and a rear returnflue in communication with the lower shelf to receive a second airflowfrom the air return duct.
 13. The refrigerated merchandiser of claim 12,wherein the case includes a plurality of rear discharge flues and aplurality of rear return flues alternatingly positioned across ahorizontal length of the case such that one rear discharge flue ispositioned adjacent at least one rear return flue.
 14. The refrigeratedmerchandiser of claim 10, wherein the lower shelf defines at least twoair return ducts configured to receive at least a portion of the secondair curtain from the upper shelf, the lower shelf further defining oneair discharge duct configured to discharge a third air curtain generallydownward toward the base.
 15. The refrigerated merchandiser of claim 14,wherein the air discharge duct is located substantially below the airreturn ducts.
 16. The refrigerated merchandiser of claim 10, wherein theupper shelf defines at least two air return ducts configured to receiveat least a portion of the second air curtain from the canopy.
 17. Therefrigerated merchandiser of claim 10, further comprising an evaporatorcoupled to the case and configured to refrigerate an airflow within thecase, and wherein the case defines a primary passageway having a firstportion configured to direct the airflow toward the canopy, and a secondportion configured to direct the airflow toward the upper shelf.
 18. Amethod of conditioning a product display area of a refrigeratedmerchandiser, the method comprising: providing a case including a basedisposed below the product display area and a canopy disposedsubstantially above the product display area; providing a shelfsupported by the case within the product display area; discharging afirst air curtain generally downward from the shelf into the productdisplay area toward the base; discharging a second air curtain generallydownward into the product display area from above the shelf; andreceiving at least a portion of the second air curtain via an air returnduct of the shelf.
 19. The method of claim 18, further comprisingdischarging a third air curtain from the canopy toward the base.
 20. Themethod of claim 18, further comprising discharging the first air curtainand the second air curtain toward the base a distance less than the fullheight of the product display area.
 21. The method of claim 18, furthercomprising distributing a first portion of an airflow through the casetoward the canopy; and distributing a second portion of the airflowthrough the case toward the shelf.